Autopilot Servo Installation Guide

Sonex/Waiex-Pitch

This product is not approved for installation in type certificated aircraft 

Document 101865‐000, Revision A 

August, 2012

Copyright © 2009-2013 by Dynon Avionics, Inc.

Permission to print this this manual is granted to third parties

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2008‐2012 Dynon Avionics, Inc. All rights reserved. No part of this manual may be reproduced, copied, transmitted, disseminated or stored in  any storage medium, for any purpose without the express written permission of Dynon Avionics. Dynon Avionics hereby grants permission to  download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed for  personal use, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copyright notice  and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited.  

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Servo Mounting Instructions – Sonex Pitch Kit

101865-000 Rev A

1

SERVO MOUNTING INSTRUCTIONS – SONEX/WAIEX PITCH KIT

Kit Contents

Dynon Part # QTY Part Description

100836-000

100966-002

100975-002

100976-007

1 Male Rod End 3/16” ID

1 Tube Aluminum Pushrod – 4.0”

2 AN315-4R Jam Nut

4 AN365-832A Nylon Insert Locknut

100977-000

100978-002

100978-003

100978-004

100979-002

100981-000

100981-005

101197-022

101443-000

101612-000

101843-000

101877-000

101880-000

6 AN970-3 Large Flat Washer

4 AN960-8 Small Flat Washer #8

6 AN960-10 Small Flat Washer

2 AN960-416 1/4" Flat Washer

4 MS35333-39 #10 Internal Star Washer

4 AN3H-3A Bolt - 3/8"

1 AN3H-10A Bolt - 1"

1 Bolt Hex #1/4-28 3-5/32” AN4-31A

1 Male Rod End 1/4” ID

1 Pitch Servo Floor Plate

1 AN364-428A Nylon Insert Locknut

7 Cherry N Rivets - CCP-42

4 Screw Washer Head AN525-832R8

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

2

SERVO INSTALLATION AND CONFIGURATION

The Sonex/Waiex pitch servo mounting kit includes a servo mounting bracket, fuselage floor doubler, connecting hardware, and push rod required to complete the installation of the Dynon pitch servo into a dual control Sonex/Waiex aircraft. All Dynon-supplied parts are shaded in the installation illustration (Fig 1) to distinguish them from existing aircraft hardware and structure.

If the builder is attempting to install the servo in an aircraft configuration other than that shown, modifications to the kit may be required.

SUGGESTED INSTALLATION PROCEDURE

Read Instructions

INVENTORY

PARTS

ASSEMBLE

PUSHROD

ATTACH PUSHROD

TO CONTROL

STICK FRAME

INSTALL SERVO

FLOOR PLATE

DO YOU HAVE FULL

AND UNOBSTRUCTED

MOVEMENT?

NO

POSITION SERVO

ON FLOOR PLATE

YES

ATTACH SERVO

TO PUSHROD

INSTALL SERVO

MOUNTING BRACKET

TO FLOOR PLATE

INSTALL SERVO IN

MOUNTING BRACKET

SERVO

CALIBRATION

Complete

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

3

All AN bolts supplied by Dynon have drilled heads for use with safety wire. With the servo in place, torque all fasteners to installation specifications and add safety wire where needed.

To prevent the possibility of the servo arm going over-center, the servo arm must not travel more than a total of +/-60º from neutral throughout the control system's range of travel. Most installations use the outer most hole on the servo arm, due to variations in mounting plate and servo bracket installation locations, each install varies. The linkage should be installed such that adequate force is applied to the control stick frame with the pushrod perpendicular to both the servo and the control stick frame. Changing the location of the pushrod mounting on the servo arm will affect servo torque output, servo arm travel, control surface resolution, and the amount of force required to shear the safety screw, the installer should have an understanding of these implications. See Fig 2 which illustrates the linear travel and available force for each mount point on standard-arm servos.

The distance between the servo arm and the control system attachment point must allow for the angle between the servo arm and the push rod to be at approximately 90º when the controls are at neutral. Use the adjustability in the rod ends to achieve this, and then tighten the jam nuts to lock the rod ends in place. Installers should always keep in mind the range of motion of the servo.

Total servo arm travel is limited, but verify the arm/linkage do not interfere with anything during the full motion of the control stick. The built in control stops of the aircraft will limit the servo arm travel when installed correctly. We recommend the use of the optional Range of Motion

Limiting Bracket, supplied with the servo to eliminate the chance of the servo arm going overcenter. This bracket should not be used as a normal stop; the aircraft's built-in stops should always be the primary range limit.

For the latest documentation on all Dynon products go to dynonavionics.com

. Please read through that documentation to understand the wiring and configuration process for your Autopilot system. We also maintain a collaborative set of this documentation, which is often updated with new information by both Dynon and fellow builders. Visit wiki.dynonavionics.com

to view and contribute to the latest version of these documents.

You can also visit forum.dynonavionics.com

to discuss and share installation notes, pictures, and suggestions with other builders.

Neglecting to properly install and/or use Dynon autopilot hardware may result in failures which could cause loss of aircraft control resulting in aircraft damage, personal injury or death.

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

4

Fig 1

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

5

Wiring Overview

The following diagram provides an overview of the autopilot-specific wiring installation. For the complete set of wiring and configuration instructions, please see the latest Installation Guide for your Dynon EFIS product. For a SkyView system please reference the Autopilot Servo

Installation, Configuration, and Calibration chapter of your SkyView System Installation guide. For EFIS-D10A, EFIS-D100 or FlightDEK-D180 please reference the Autopilot

Installation and Configuration chapter of each respective Installation Guide.

Use 22 AWG wire for SkyNet and Disengage signals.

Twisted Pair

Use appropriate wire gauge for servo power based on current consumption and length of wire run D10A/D100/D180

D25

CONNECTOR

SKYVIEW

D9

CONNECTOR

N/A

N/A

5

4

4

8

6

1

WHT/BLU

WHT/GRN

BLU

GRN

Wht/Blu

Wht/Grn

Blue

Green

Aircraft GND

Pilot-accessible

Disengage/CWS button

(Normally open, momentary)

Usually mounted to the stick

Aircraft Power (10-30V)

Pilot-accessible

Servo Power

Switch/Breaker

Servo 1

Wires

Red Power (10-30V)

Aircraft GND Black Ground

Green SkyView Network 1 A or DSAB A

Blue SkyView Network 1 B or DSAB B

Twisted Pair

Yellow Disengage

Wht/Grn SkyView Network Data 2 A *

Wht/Blu SkyView Network Data 2 B *

Optional resistor for detecting broken disengage lines

5 kohm

Servo Current Draw at 12V

(halve the current values for 24V systems)

SV32

Powered but disengaged: 0.1 amps

Engaged and holding, 100% torque: 0.80 amps

Engaged and moving, 100% torque: 1.33 amps

SV42

Powered but disengaged: 0.1 amps

Engaged and holding, 100% torque: 1.11 amps

Engaged and moving, 100% torque: 2.03 amps

SV52

Powered but disengaged: 0.1 amps

Engaged and holding, 100% torque: 1.52 amps

Engaged and moving, 100% torque: 2.80 amps

Twisted Pair

Pitch and Roll Servos are wired identically, and can share wiring for convenience at any point along the run.

Aircraft GND

*NOT USED FOR D10A/D100/D180

Wires

Servo 2

Red

Power (10-30V)

Black Ground

Green SkyView Network 1 A or DSAB A

Blue SkyView Network 1 B or DSAB B

Yellow Disengage

Wht/Grn SkyView Network Data 2 A *

Wht/Blu SkyView Network Data 2 B *

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

6

Linkage mount position force and travel

The diagram below illustrates the maximum travel and force available at each linkage mounting point. As can be seen, the closer you mount the linkage to the shaft, the more force the servo can deliver. However, this also means the travel of the arm is shorter. Again, ensure that the servo arm is nowhere near going over-center throughout the entire range of the control system.

Modify mount position with caution and take all precautions to ensure that a near over center condition cannot occur.

SERVO MOUNTING BRACKET DETAIL

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

Standard Arm

Max Linear Travel

A: 2.6”, B: 2.2”, C: 1.8”

Max Force @ 100% Torque

SV32 - A: 24lb, B: 29lb, C: 36lb

SV32-Weight 2lb

SV42-Weight 3lb

SV52-Weight 4lb

7

The autopilot safety shear screw should NEVER be removed or adjusted during this operation. If the shear screw has broken and needs replacement, there is specific documentation available for this purpose at http://docs.dynonavionics.com

.

Servo Mounting Instructions – Sonex/Waiex Pitch Kit

101865-000 Rev A

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